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39

COMMISSIONING AND MAINTENANCE

3.6

Cleaning and servicing the boiler

It is essential to clean the boiler and remove carbon deposits

from the surfaces of the heat exchanger in order to keep the

boiler efficient and economical.

9

All cleaning operations MUST be performed under the fol-

lowing conditions:

− boiler cold

− boiler switched OFF

− Suitable personal protection equipment

Perform the following operations before beginning any mainte-

nance or cleaning:

− Turn the mains power switch OFF and turn the control

panel function selector OFF (0);

− close all external fuel shut-off cocks.

3.7

Annual cleaning

3.7.1

Cleaning and maintaining the burner

Proceed as follows to access the internal parts of the boiler:

− Remove the front panel (1);

1

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Содержание 20116107

Страница 1: ...cod 20119283 rev 2 07 2016 INSIEME EVO 32 BS 100 LN EN INSTALLATION AND MAINTENANCE MANUAL ...

Страница 2: ... the following di rectives Directive 92 42 EEC on efficiency requirements Electromagnetic Compatibility Directive 2014 30 EU Low Voltage Directive 2014 35 EU Ecodesign Directive 2009 125 CE for energy related prod ucts Energy Labelling Directive 2010 30 EU Delegated Regulation EU N 811 2013 Delegated Regulation EU N 813 2013 Delegated Regulation EU N 814 2013 9 9This product must only be used for ...

Страница 3: ...rcuit 17 2 8 Typical water system schematics 18 2 9 Fuel connections 18 2 10 Flue gas vent and comburent air intake 20 2 10 1 Technical specifications of stack 21 2 10 2 Connection to the stack 21 2 11 System filling and emptying 22 2 11 1 Water quality requirements 22 2 11 2 Filling 22 2 11 3 Emptying 23 2 12 Wiring diagram 24 2 13 Electrical connections 25 3 COMMISSIONINGAND MAINTENANCE 27 3 1 P...

Страница 4: ... another Owner or User or trans ferred to another plant If it is damaged or lost request an other copy from your local Technical Assistance Service R 1 2 Precautions The operation of any appliance that uses fuel electrical power and water demands that a number of fundamental safety pre cautions be respected 0 0Do not allow children or infirm persons to operate the sys tem unsupervised 0 0It is for...

Страница 5: ...eating of do mestic hot water in the storage tank An electronic burner controller that monitors the correct functioning of the selected burner program and sends a lockout signal to the control panel in the event of an error 9 9The intervention of a safety device indicates a potentially dangerous malfunction in the system Contact the manu facturer s Technical Assistance Service immediately 9 9Safet...

Страница 6: ...rain cock 9 Storage cylinder fill cock 10 Storage cylinder expansion vessel 11 Storage cylinder inspection flange 12 Storage cylinder flange insulation 13 Central heating circuit pump 14 Non return valve 15 Boiler circulator 16 Boiler body 17 Flame inspection window 18 Oil burner 19 Storage cylinder with insulation 20 Storage cylinder sensor socket 21 Storage cylinder safety valve 22 Storage cylin...

Страница 7: ...seal 5 Air damper adjuster screw 6 Oil pump pressure adjuster screw 7 Pressure gauge fitting 8 Photoresistor 9 Combustion head 10 Motor 11 Air intake OIL PUMP 7 6 5 4 3 2 1 8 1 Suction port 2 Return 3 By pass screw 4 Pressure gauge fitting 5 Pressure adjuster screw 6 Vacuum gauge fitting 7 Valve 8 Auxiliary pressure measurement fitting ...

Страница 8: ... to LCV 96 5 Annual energy consumption QHE 104 8 GJ Daily electrical energy consumption Qelec 0 1 kWh Annual electrical energy consumption AEC 29 kWh Daily fuel consumption Qfuel 26 3 kWh Annual fuel consumption AFC 36 GJ Noise level sound power LWA 59 dB A Emissions at maximum heat input NOx referred to HCV 105 mg kWh CO2 12 5 CO w a 10 ppm Flue gas T At Pn 60 80 C 100 C Smoke scale 0 5 Flue gas ...

Страница 9: ... with storage cylinder at 60 C 180 l Specific flow rate EN 13203 19 l min Replenishment time with T 35 C 12 min Maximum operating pressure of storage cylinder 6 bar Volume of expansion vessel CH 2 l Precharge of expansion vessel CH 3 5 bar Inlet water temperature 10 C and average outlet water temperature 45 C with coil inlet temperature of 80 C 1 8 Central heating system pump DESCRIPTION INSIEME E...

Страница 10: ... 1 0 2 0 3 0 4 0 5 0 Q l s 10 20 30 40 50 W P1 Residual head Flow rate 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 Q m h 0 0 0 2 0 4 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 The curves refer to a water density of 983 2 Kg m3 a water temperature of 20 C and a kinematic viscosity of 0 474 mm2 s 0 474 cSt ...

Страница 11: ... Boiler thermostat sensor Tm Minimum temperature thermostat sensor TS Safety thermostat sensor TL Maximum temperature thermostat sensor 1 Boiler temperature gauge 2 Storage cylinder temperature gauge 3 Storage cylinder thermostat sensor 4 Boiler temperature gauge socket ...

Страница 12: ... 82 C 55 82 5 Electrical power indicator green Lights to show that the boiler is receiving electrical power 6 Burner lockout indicator red Lights to show that the burner locked out 7 Summer I Winter II selector 8 Storage cylinder temperature gauge Displays the temperature of the domestic hot water in the storage cylinder 9 Manual reset for safety thermostat Allows you to reset the boiler if the sa...

Страница 13: ...rts catalogue Hydraulic test certificate Energy label 2 1 1 Positioning of labels A A Packing label 9 9The instruction manual is an integral part of the boiler Once located read it thoroughly and keep it safe 9 9Keep the documentation envelope in a safe place Any re placement documents must be ordered from Riello S p A who reserve the right to charge for the cost of the replace ment 2 2 Overall di...

Страница 14: ... A fixing the packing to the pallet A remove the cardboard packing and non scratch cloth 0 0Do not dispose of packaging material into the environment or leave it within the reach of children since it can become a potential hazard Dispose of packaging material in com pliance with applicable legislation With the packing removed remove the front panel 1 1 Locate the bag containing the documentation r...

Страница 15: ...door location provided the flue gases vent pipe and comburent air pipe are connected to the outdoors Under such conditions the room does not require air vents 9 9When installing the boiler allow sufficient space around it to access all safety and control devices and to permit easy maintenance 9 9Check that the appliance s electrical protection level is suit able for the place of installation 9 9Ma...

Страница 16: ...ther details Make sure that the electrical supply system has been in stalled by a qualified electrician in compliance with ap plicable standards Make sure that the fuel feed line and any storage tank are made and installed in compliance with applicable standards Make sure that expansion vessels are big enough to con tain the additional volume generated by thermal expan sion Make sure that the flow...

Страница 17: ...2 BS 100 LN A 85 mm B 125 mm C 235 mm D 395 mm E 950 mm F 1020 mm G 45 mm MI CH flow 1 M Ø RI CH return 1 M Ø UACS domestic hot water outlet 1 2 M Ø RC recirculation 1 2 M Ø EAFS domestic cold water inlet 1 2 M Ø SC drain 10 Ø 2 7 Boiler water circuit CENTRAL HEATING RETURN CENTRAL HEATING FLOW DHW outlet DHW circulation Domestic cold water inlet 8 10 8 9 7 7 5 5 6 4 3 2 1 1 Boiler body 2 Automati...

Страница 18: ...urn pipe to the fitting 2 Make sure that these connections are oil tight 565 600 2 1 Description INSIEME EVO 32 BS 100 LN Fittings 2x3 8 M Ø If the oil feed system is in negative pressure the return line must reach the same height as the suction line This avoids having to install a bottom valve which would be essential if the return hose were to be located above the level of the fuel 9 9The instal...

Страница 19: ...ignition cycle again up to the ignition of the flame max 4 m H H Automatic shut off device if fitted For details of the electrical connections see the Automatic shut off device DAI section on page 24 H m L m Øi 8mm Øi 10mm 0 35 100 0 5 30 100 1 25 100 1 5 20 90 2 15 70 3 8 30 3 5 6 20 H Height difference L Maximum length of suction hose Øi Internal diameter of hose 1 Suction port 2 Return 3 By pas...

Страница 20: ...ensate drain system 3 must conform to national and local legislation and standards 9 9The stack fitting is equipped with a seal A Do not use pipes with riveted overlaps to construct the flue A 280 80 125 70 Øe 80 Øi 120 INSIEME EVO 32 BS 100 LN boilers are designed to function with comburent air drawn from outdoors If comburent air is drawn from outdoors the appliances are type C sealed and the bo...

Страница 21: ...sation and the cooling of flue gases the stack must have a dedicated condensate drain sys tem at the bottom 9 9The diameter of the stack must never be smaller than that of the flue pipe from the boiler 2 10 2 Connection to the stack The boiler must be connected to the stack using rigid flue pipes that are resistant to heat condensate and mechanical stress All joins must be sealed and the finished ...

Страница 22: ...cified in the table it is mandatory to install a water softening system 9 9Excessive water softening leading to a total hardness 15 F can cause corrosion in metal parts pipes and boiler com ponents Keep the electrical conductivity of the water un der 200 µS cm 0 0Do not top up the central heating circuit on a frequent or continuous basis as this can damage the boiler s heat ex changer The use of a...

Страница 23: ... and turn the control panel function selector to 0 Close the water supply shut off cocks To empty the boiler connect a rubber hose Øint 12mm to the hose union on the boiler drain cock 1 or storage cylinder drain cock 2 then open the cock 1 2 NOTE Open a hot water tap to facilitate emptying the storage cylinder ...

Страница 24: ... K R AE Power supply COM G 3 position function selector COM E I Summer Winter selector TS Safety thermostat 100 C 0 6 Tm Minimum temperature thermostat 50 C TR Boiler control thermostat 55 82 C LV Mains power indicator LR Burner lockout indicator FU Mains power fuse 6 3 A T CO1 CO7 Multi connectors TL Maximum temperature thermostat MO1 Terminal strip PB Boiler circulator PI Central heating system ...

Страница 25: ...eed as follows to access the control panel terminals Remove the front and top panels A and B from the boiler casing A B loosen the two two screws C securing the instrument panel to the casing of the control panel C open the door D and rotate the instrument panel E outwards E D to facilitate electrical connections remove the two screws F and remove the terminal holder G from the casing H F G H rout...

Страница 26: ...s contact opening of at least 3 mm Respect the connection L line N neutral Keep the earth conductor 2 cm longer than the power supply con ductors Use cables with a section greater than or equal to 1 5 mm2 complete with cable terminal caps Refer to the wiring diagrams in this manual for all electric operations Connect the equipment to an effective earthing system 0 0It is strictly forbidden to use ...

Страница 27: ...o start up the boiler for the first time turn the boiler s mains power switch ON Set the room thermostat to the required temperature 20 C or if the system has a timer or timer thermostat make sure that this is switched ON and adjusted to the required temperature 20 C Open the control panel access door Adjust the boiler and storage cylinder thermostats to about the middle of the section with three ...

Страница 28: ...e the cause of the overheating before restarting the boiler 3 3 Checks during and after initial start up Once the boiler has started up make sure that it shuts down and re starts properly when The boiler thermostat and storage cylinder thermostat settings are changed The function selector is moved from position I to 0 and back 20 100 4 40 60 80 3 2 1 0 0 120 20 100 4 40 60 80 3 2 1 0 0 120 The Sum...

Страница 29: ...rical power consump tion as shown in the table Nr displayed Meaning power LED 1 flashing green Standby 0 LED 1 green and LED 2 yellow both lit Low load 0 25 LED 1 green and LEDs 2 3 yel low all lit Low medium load 25 50 LED 1 green LEDs 2 3 4 yel low all lit Medium high load 50 75 LED 1 green LEDs 2 3 4 5 yellow all lit High load 75 100 The pump functions at fixed speed Alarm display If the pump d...

Страница 30: ...the LEDs except the red LED flash for one second to indicate that the button lock function has been activated deactivated Setting mode To modify settings press the button 1 for between 2 and 10 seconds Users can only select new settings provided the button lock function is disabled Available settings are displayed in a pre defined sequence that is repeated everytime the button is brieflypressed an...

Страница 31: ...n verification time time following start up of main power supply t2l Check for extraneous light or false flame signal dur ing t2 the burner controller waits for time t2 then enters lockout the motor does not start t2p Maximum fuel oil pre heating time the burner controller waits for time t2p then enters lockout t3 Pre purging time the fan motor runs then the fuel oil valve opens t3l Check for extr...

Страница 32: ...t up after pre heating FM Fan motor ID Ignition electrode V Fuel oil valve F Flame detector LED Colour of button LED Lockout caused by extraneous light during pre purging F LED HT FM ID P V M K PH Lockout Red Flashing green Flashing orange POWER ON Flashing green red t1 t2 t3l ts Cycle times t0 t1 1 t2 3 5 t2l 25 t2p max 600 t3 15 t3l 25 t3i 2 ts 5 t4i 10 t4l 1 t5i 3 0 4 0 8 tr 3 repeats tpp 60 Ti...

Страница 33: ...OM fault ORANGE GREEN alternate flashing Slow 0 5 0 5 Fault diagnosis lockouts Description of lockout Lockout time Presence of extraneous light during standby After 25 seconds Pre heating not finished After 600 seconds Detection of extraneous light during pre purging or pre heating After 25 seconds Detection of extraneous light during pre heating After 25 seconds Flame not detected by end of safet...

Страница 34: ...ng Mode POST PURGING The post purging function keeps the fan running for a set time after the burner shuts down provided there is no new heat re quest When the contacts of the heat request thermostat open the burner controller shuts down the flame and shuts off the oil supply Post purging does not occur after a lockout if a heat request is cancelled during pre purging Post purging occurs if a heat...

Страница 35: ...t 10 sec RED led Blinking 2 times 0 2s ON 0 2s OFF Release the button The burner shuts down and restarts The burner shuts down then restarts automatically Each shut down test resets zeroes the ignition cycle count No LEDs flash when you exit the shutdown test menu POST PURGING Post purging time can be set to a maximum of 120 seconds To set post purging time proceed as follows Post purging programm...

Страница 36: ...eceives a new heat request while it is repeating the ignition cycle the ignition attempt count is reset when the heat request thermostat trips NOTE Note If the burner functions continuously for 510 seconds the controller is allowed one additional startup attempt Disconnect and reconnect power to the burner to obtain a fur ther complete series of startup attempts max 3 for the next heat request EXT...

Страница 37: ... error is detected during normal functioning the burner shuts down and does not restart The error is sig nalled If an error is detected while the burner is already locked out no signal is displayed but the burner cannot be re set The LED stops flashing as soon as the error disap pears EEPROM CONTROL The burner controller automatically checks for errors in the mi crocontroller EEPROM and enters loc...

Страница 38: ...60 80 3 2 1 0 0 120 Turn the room thermostat to about 10 C or select the frost protection function Turn the storage cylinder thermostat to about the middle of the section with one line 20 40 60 80 100 0 120 3 5 Preparing for extended periods of disuse If the boiler is not going to be used for an extended period of time proceed as follows to prepare it for shut down Open the control panel access do...

Страница 39: ...performed under the fol lowing conditions boiler cold boiler switched OFF Suitable personal protection equipment Perform the following operations before beginning any mainte nance or cleaning Turn the mains power switch OFF and turn the control panel function selector OFF 0 close all external fuel shut off cocks 3 7 Annual cleaning 3 7 1 Cleaning and maintaining the burner Proceed as follows to ac...

Страница 40: ...REMOVING THE BLAST TUBE Proceed as follows to remove the blast tube Remove the screws 1 and remove the blast tube disconnect the high voltage cable 2 1 2 9 9With the blast tube removed check its front edge to make sure that it is smooth free from deposits burns and dents Reverse the above steps to reassemble REPLACING THE NOZZLE INSIEME EVO 32 BS 100 LN Nozzle type 0 65 80 HF Remove the blast tube...

Страница 41: ...ceed as follows Loosen the screw 1 open the cover 2 and remove all the components inside Remove the coil 3 Unscrew and remove the two screws 4 2 1 3 4 4 CLEANING THE FAN 9 9Clean the inside and the rotor blades of the fan unit to re move any build up of dust Accumulated dust reduces the air flow and therefore reduces combustion efficiency lead ing to increased emissions 9 9Take care not to damage ...

Страница 42: ...s box 2 4 5 3 remove the turbulators 6 and check them for wear and fin angle replace as necessary use a flue brush 7 or other suitable tool 6 7 remove any displaced soot through the combustion chamber hole Proceed as follows on completion of cleaning check the condition of the flame guard 8 Replace as necessary refit the turbulators in the flue gas pipes making sure that they are correctly seated ...

Страница 43: ...ugh the storage cylinder drain cock Remove the insulation from the storage cylinder flange Pull the sensors out of their sockets Remove the screws 2 fixing the flange 3 in place and remove the flange 1 2 3 Clean inside the storage cylinder and remove any resi dues through the access hole Check the magnesium anode 4 for wear Replace if nec essary Check the condition of the sensor holders 5 Check th...

Страница 44: ...does not reach its tempera ture setpoint Boiler dirty Clean Burner capacity insufficient Check and adjust the burner Problem with boiler control thermostat Check correct functioning Check the temperature setting The generator triggers a thermal safety block Problem with boiler control thermostat Check correct functioning Check the temperature setting Check the electrical wiring Check the position ...

Страница 45: ...c hot water Supply pressure too high Fit a pressure reducer Flow rate too high Fit a flow reducer Limescale and or sludge in storage cyl inder Check and clean Check the functioning of the DHW circuit pump Check the settings of the control ther mostats Check the position of the sensor bulbs Check boiler operating temperature The central heating or DHW pump is not working Pump seized Electrical conn...

Страница 46: ... extraneous light Eliminate cause of light or false flame signal The burner performs pre purging and ignition correctly but locks out after about 5 seconds RED Flame detector dirty Clean the flame de tector The flame detector is faulty Change as necessary The flame detaches or fails Check fuel oil pressure and flow rate Check the air flow Change the nozzle Check solenoid valve coil The burner star...

Страница 47: ...47 ...

Страница 48: ...Tel 0442630111 Fax 044222378 www riello it The manufacturer strives to continuously improve all products Appearance dimensions technical specifications standard equipment and accessories are therefore liable to modification without notice ...

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